Senior Mechanical Design & GD&T Engineer

KARTHIKEYAN K

SENIOR MECHANICAL DESIGN ENGINEER

Madurai, Tamil Nadu, India +91-904**-***** *********@*****.*** PROFESSIONAL SUMMARY

Senior Mechanical Design Engineer with 12+ years of experience across aerospace, automotive, and electromechanical/semiconductor systems. Deep expertise in GD&T (ASME Y14.5), 1-D and 2-D tolerance stack- up analysis (worst-case, RSS, and 6-sigma methods), DFM/DFA, and CAD-to-release workflows using CATIA V5, NX, and Creo. Proven track record reducing rework, resolving interference/fit issues at the assembly level, and accelerating drawing release through PLM systems (Teamcenter). Lean Six Sigma Green Belt with strong cross- functional collaboration skills, supporting design, manufacturing, quality, and FEA teams. CORE COMPETENCIES

GD&T (ASME Y14.5-1994/2009) & Datum Strategy (3-2-1 Principle)

Tolerance Stack-Up Analysis — Linear & Radial, 1-D/2-D, Worst-Case, RSS, 6-Sigma

DFM / DFA / DFMEA and Design for Quality

CAD Platforms: Proficient in CATIA V5, Siemens NX (9/11), PTC Creo (Part, Sheet metal)

PLM & Change Management: Siemens Teamcenter, ECN/ECR Processing, E-BoM

Fixture & Gage Design for Quality Inspection and Validation

First Article Inspection (FAI), AS9100 Audit Documentation

Lean Six Sigma Green Belt — Process & Quality Improvement

Engineering drawing quality checking at individual part and assembly level.

FEA Geometry Clean-Up Support for Simulation Accuracy and static structural FEA analysis CERTIFICATIONS & LICENSES

The American Society of Mechanical Engineers certified GD&T Technologist Engineer (ASME Y14.5- 2009R)

Lean Six Sigma Green Belt — Certified by MSME, Government of India / Indian Society for Technology Development Centre

PROFESSIONAL EXPERIENCE

Senior Analyst, Engineering R&D — HCL Technologies Jan 2019 – Present Chennai, Tamil Nadu Projects worked: VOLVO AUTOMOTIVE

Mentor and review CAD models and drawings of engine components and exhaust system created by junior design engineers on GD&T application and stack-up methodology, signing off on drawings before PLM release

Act as point of contact for design queries from the VOLVO account teams, coordinating with cross-functional stakeholders (manufacturing, quality, program management) to close out design issues

Lead root-cause investigation for recurring interference/fit issues, presenting findings and corrective action plans to engineering leadership

Reduced drawing rework cycles by identifying tolerance-related defects earlier in the design review stage

Standardized tolerance stack-up templates/checklists, cutting analysis turnaround time for the team

Contributed to on-time delivery of drawing releases per quarter while maintaining zero critical non- conformances

Participate in DFMEA sessions to flag high-risk dimensional/tolerance failure modes before drawing release

Coordinate with quality teams on first-pass-yield improvement by addressing root-cause dimensional variation Senior Engineer — QuEST Global Engineering Pvt. Ltd. Nov 2017 – Nov 2018 Bengaluru, Karnataka Project: Mercedes-Benz India

Delivered CAD execution and detailing support for Mercedes Benz engine components like brackets, valve covers, core plugs, and oil pans etc. Using Siemens NX9, with PLM management in Siemens Teamcenter.

Defined part/assembly product definitions through datum assignment and GD&T determination, ensuring adherence to engineering quality standards.

Performed complex assembly-level tolerance stack-up analyses using custom MS Excel templates; reported results via worst-case, RSS (statistical), and 6-sigma bell-curve methods to identify interference/gap conditions.

Supported FEA teams with geometry clean-up to enable finer mesh quality and reduced simulation runtime without sacrificing accuracy.

Provided technical guidance to cross-functional teams and trained junior engineers on GD&T application in design and manufacturing.

Senior Engineer — Renault Nissan Technology Business Center India May 2017 – Sep 2017 Mahindra City, Chengalpattu

Conducted perceived quality assessments for automotive BIW and exterior surfaces by evaluating gap and flush conditions against design intent.

Performed tolerance stack-up studies to identify interference and clearance conditions between mating parts, confirming form and fit within specification limits.

Created powertrain assembly and individual part manufacturing drawings using CATIA V5. System Engineer, Engineering R&D Vertical — Tata Consultancy Services Feb 2014 – Jan 2017 Chennai, Tamil Nadu Projects: Renault Nissan Technology Business Center India

Created drawings for BIW fixture and inspection devices and powertrain components in CATIA V5 as her manufacturing standard.

Designed and detailed engine components and exhaust assemblies in CATIA V5; performed complex linear and radial tolerance stack-up analyses to verify part/assembly-level interference clearance for powertrain sub- assemblies.

Released part- and assembly-level drawings through Siemens Teamcenter and generated E-BoMs to support manufacturing and assembly planning.

Processed client-initiated Engineering Change Notices (ECNs), documenting corrective changes to affected parts/assemblies per standard Teamcenter formats.

Design Engineer — Kerns Aero Products Pvt. Ltd. (a Wayne Burt Group company) May 2011 – Feb 2014 Chennai, Tamil Nadu Project: GE Aviation (Manufacturing & Quality)

Created 2D cross-sections, 3D CAD models, and engineering drawings for cast and sheet-metal aero engine components in CATIA V5, applying GD&T per ASME Y14.5-1994 to support manufacturing, tooling, and inspection.

Developed process flow maps in collaboration with manufacturing and production teams to streamline component production.

Conducted First Article Inspection (FAI) reporting for new production parts, validating dimensional accuracy, GD&T tolerance, and surface finish.

Supported fixture design and AS9100 audit documentation as a member of the Engineering Center of Excellence (CoE), partnering with cross-functional production teams. EDUCATION

Bachelor of Engineering, Aeronautical Engineering

Jun 2007 – May 2011 Vel Tech Engineering College, Anna University CGPA: 7.45 (70.56%) LANGUAGES

English Tamil

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